PowerPro Gasoline Engines

Operation, Repair, and Parts Manual

Form L-1512(9-07)

PowerPro Model Number 160, 200, 270 and 390HY160 (5.5 hp) - 2541-0043 (3/4” keyed shaft)

2541-0044 (5/8” threaded shaft)

HY200 (6.5 hp) - 2541-0045 (3/4” keyed shaft)

2541-0046 (5/8” threaded shaft)

HY270 (9.0 hp) - 2541-0047 (1” keyed shaft)

HY390 (13.0 hp) - 2541-0048 (1” keyed shaft)

2541-0049 (1” keyed shaft w/electric start)

2541-0050 (1” threaded shaft)

2541-0051 (1” threaded shaft w/electric start)

Note: Unit is not shipped with oil. Please add oil to engine prior to operating.

ENGINE SAFETY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

COMPONENTS & CONTROL LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

CHECK BEFORE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

STORAGE/TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

TECHNICAL & CONSUMER INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

ENGINE REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

OPTIONAL PARTS – BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

READ THIS OWNER’S MANUAL CAREFULLY. Pay special attention to these symbols and any instructions that follow:

Indicates serious injury or death will result if instructions are not followed.

Indicates a strong possibility that serious injury or death could result if instructions are not followed.

Indicates a possibility that minor injury could result if instructions are not followed.

Indicates that equipment or property damage can result if instructions are not followed.

Gives helpful information.

Table of Contents

3

IMPORTANT SAFETY INFORMATION

Most accidents with engines can be prevented ifyou follow all instructions in this manual and on theengine. Some of the most common hazards arediscussed below, along with the best way to protectyourself and others.

Owner Responsibilities

• The engines are designed to give safe anddependable service if operated according toinstructions. Read and understand this owner’smanual before operating the engine. Failure to doso could result in personal injury or equipmentdamage.

• Know how to stop the engine quickly, and under-stand the operation of all controls. Never permitanyone to operate the engine without properinstructions.

• Do not allow children to operate the engine. Keepchildren and pets away from the area of operation.

Refuel with Care

Gasoline is extremely flammable, and gasolinevapor can explode. Refuel outdoors, in a well-venti-lated area, with the engine stopped. Never smokenear gasoline, and keep other flames and sparksaway. Always store gasoline in an approved con-tainer. If any fuel is spilled, make sure the area isdry before starting the engine.

Hot Exhaust• The muffler becomes very hot during operationand remains hot for a while after stopping theengine. Be careful not to touch the muffler while itis hot. Let the engine cool before storing it indoors.

• To prevent fire hazards and to provide adequateventilation for stationary equipment applications,keep the engine at least 3 feet (1 meter) away frombuilding walls and other equipment during opera-tion. Do not place flammable objects close to theengine.

Carbon Monoxide Hazard

Exhaust gas contains poisonous carbon monoxide.Avoid inhalation of exhaust gas. Never run theengine in a closed garage or confined area.

Other Equipment

Review the instructions provided with the equip-ment powered by this engine for any additionalsafety precautions that should be observed in con-junction with engine startup, shutdown, operation,or protective apparel that may be needed to oper-ate the equipment.

Engine Safety Information

4

Components & Control Locations

5

Fuel Valve Lever

The fuel valve opens and closes the passagebetween the fuel tank and the carburetor. The fuelvalve lever must be in the ON position for theengine to run. When the engine is not in use, leavethe fuel valve lever in the OFF position to preventcarburetor flooding and to reduce the possibility offuel leakage.

Throttle Lever

The throttle lever controls engine speed. Movingthe throttle lever in the directions (shown below)makes the engine run faster or slower.

Engine Switch

The engine switch enables and disables the ignitionsystem. The engine switch must be in the ON posi-tion for the engine to run. Turning the engine switchto the OFF position stops the engine.

Choke Lever

The choke lever opens and closes the choke valvein the carburetor. The CLOSE position enriches thefuel mixture for starting a cold engine. The OPENposition provides the correct fuel mixture for opera-tion after starting and for restarting a warm engine.

Some engine applications use a remotely-mountedchoke control rather than the engine-mountedchoke lever shown here.

Recoil Starter Grip

Pulling the starter grip operates the recoil starter tocrank the engine.

Controls

6

IS YOUR ENGINE READY TO GO?

For your safety, and to maximize the service life ofyour equipment, it is very important to take a fewmoments before you operate the engine to checkits condition. Be sure to take care of any problemyou find, or have your servicing dealer correct it,prior to operating the engine.

Improperly maintaining this engine, or failing to correct a problem before operation, couldcause a malfunction in which you could be seriously injured.

Always perform a preoperation inspectionbefore each operation, and correct any problem.

Before beginning your preoperation checks, besure the engine is level and the engine switch is inthe OFF position.

Check the General Condition of the Engine

• Look around and underneath the engine for signsof oil or gasoline leaks.

• Remove any excessive dirt or debris, especiallyaround the muffler and recoil starter.

• Look for signs of damage.

• Check that all shields and covers are in place,and all nuts, bolts, and screws are tightened.

Check the Engine

• Check the engine oil level. Running the enginewith a low oil level can cause engine damage. TheLow Oil Sensor (applicable engine types) will auto-matically stop the engine before the oil level fallsbelow safe limits. However, to avoid the inconven-ience of an unexpected shutdown, always checkthe engine oil level before startup.

• Check the air filter. A dirty air filter will restrict airflow to the carburetor, reducing engine perform-ance.

• Check the fuel level. Starting with a full tank willhelp to eliminate or reduce operating interruptionsfor refueling.

Check the Equipment Powered by thisEngine

Review the instructions provided with the equip-ment powered by this engine for any precautionsand procedures that should be followed beforeengine startup.

Check Before Operation

7

SAFE OPERATING PRECAUTIONS

Before operating the engine for the first time,please review the IMPORTANT SAFETY INFORMATION and the section titled BEFOREOPERATION.

Carbon monoxide gas is toxic. Breathing it cancause unconsciousness and even death.

Avoid any areas or actions that expose you tocarbon monoxide.

Review the instructions provided with the equip-ment powered by this engine for any safety precau-tions that should be observed in conjunction withengine startup, shutdown, or operation.

STARTING THE ENGINE

1. Move the fuel valve lever to the ON position.

2. To start a cold engine, move the choke lever tothe CLOSE position.

To restart a warm engine, leave the choke lever inthe OPEN position.

Some engine applications use a remotely-mountedchoke control rather than the engine-mountedchoke lever shown here.

3. Move the throttle lever away from the SLOWposition, about 1/3 of the way toward the FASTposition.

Some engine applications use a remotely-mountedthrottle control rather than the engine-mountedthrottle lever shown here.

4. Turn the engine switch to the ON position.

5. Operate the starter.

RECOIL STARTER (all engine types):

Pull the starter grip lightly until you feel resistance,then pull briskly.

Return the starter grip gently.

6. If the choke lever has been moved to the CLOSEposition to start the engine, gradually move it to theOPEN position as the engine warms up.

Operation

8

SETTING ENGINE SPEED

Position the throttle lever for the desired enginespeed. Some engine applications use a remotely-mounted throttle control rather than the engine-mounted throttle lever shown here.

For engine speed recommendations, refer to theinstructions provided with the equipment poweredby this engine.

STOPPING THE ENGINE

To stop the engine in an emergency, simply turn theengine switch to the OFF position. Under normalconditions, use the following procedure.

1. Move the throttle lever to the SLOW position.

Some engine applications use a remotely-mountedthrottle control rather than the engine-mountedthrottle lever shown here.

2. Turn the engine switch to the OFF position.

3. Turn the fuel valve lever to the OFF position.

Operation

9

THE IMPORTANCE OF MAINTENANCE

Good maintenance is essential for safe, economi-cal, and trouble-free operation. It will also helpreduce air pollution.

Improperly maintaining this engine, or failure tocorrect a problem before operation, can causea malfunction in which you can be seriouslyhurt or killed.

Always follow the inspection and maintenancerecommendations and schedules in thisowner’s manual.

To help you properly care for your engine, the fol-lowing pages include a maintenance schedule, rou-tine inspection procedures, and simple mainte-nance procedures using basic hand tools. Otherservice tasks that are more difficult, or require spe-cial tools, are best handled by professionals andare normally performed by a technician or otherqualified mechanic.

The maintenance schedule applies to normal oper-ating conditions. If you operate your engine underunusual conditions, such as sustained high-load orhigh-temperature operation, or use in unusually wetor dusty conditions, consult your servicing dealerfor recommendations applicable to your individualneeds and use.

MAINTENANCE SAFETY

Some of the most important safety precautions areas follows. (Note: We cannot warn you of everyconceivable hazard that can arise in performingmaintenance. Only you can decide whether or notyou should perform a given task.)

Failure to properly follow maintenance instructions and precautions can cause you to be seriously hurt or killed.

Always follow the procedures and precautionsin the owner’s manual.

Safety Precautions

• Make sure the engine is off before you begin anymaintenance or repairs. This will eliminate severalpotential hazards:

• Carbon monoxide poisoning from engineexhaust. Be sure there is adequate ventilationwhenever you operate the engine.

• Burns from hot parts. Let the engine andexhaust system cool before touching.

• Injury from moving parts. Do not run theengine unless instructed to do so.

• Read the instructions before you begin, and makesure you have the tools and skills required to per-form the maintenance.

• To reduce the possibility of fire or explosion, becareful when working around gasoline. Use only anonflammable solvent, not gasoline, to clean parts.Keep cigarettes, sparks and flames away from allfuel-related parts.

Remember that your servicing dealer knows yourengine best and is fully equipped to maintain andrepair it.

To ensure the best quality and reliability, use onlynew, genuine parts or their equivalents for repairand replacement.

Maintenance

10

REFUELING

Part Number HP Fuel Tank Capacity

2541-0043 5.5 3.6 L 0.95 Gal

2541-0044

2541-0045 6.5

2541-0046

2541-0047 9 6.0 L 1.6 Gal

2541-0048 13 6.5 L 1.7 Gal

2541-0049

2541-0050

2541-0051

With the engine stopped, remove the fuel tank capand check the fuel level. Refill the tank if the fuellevel is low.

Gasoline is highly flammable and explosive. You can be burned or seriously injured whenhandling fuel.

• Stop the engine and keep heat, sparks andflame away.• Handle fuel only outdoors. • Wipe up spills immediately.

Refuel in a well-ventilated area before starting theengine. If the engine has been running, allow it tocool. Refuel carefully to avoid spilling fuel. Do notfill above the fuel strainer shoulder. After refueling,tighten the fuel tank cap securely.

Never refuel the engine inside a building wheregasoline fumes may reach flames or sparks. Keepgasoline away from appliance pilot lights, barbe-cues, electric appliances, power tools, etc.

Maintenance

MAINTENANCE SCHEDULE

REGULAR SERVICE PERIOD First Every Every EveryPerformed at every indicated month or Each month 3 months 6 months yearoperating hour interval, whichever comes first. use or or or or

Item 20 hours 50 hours 100 hours 300 hours

• Engine oil Check level °

Change ° °

• Air cleaner Check °

Clean °(1)

Replace °†

• Sediment cup Clean °

• Spark plug Check-Clean °

Replace °

Spark arrester Clean(optional parts) °

• Idle speed Check-Adjust °(2)

• Valve clearance Check-Adjust °(2)

• Fuel tank and strainer Clean °(2)

• Combustion chamber Clean After every 300 Hrs. (2)

• Fuel line Check Every 2 years (Replace if necessary) (2)

•Emission-related items. † Replace the paper element type only.

(1) Service more frequently when used in dusty areas.

(2) These items should be serviced by your servicing dealer unless you have the proper tools and are mechanically proficient.

11

Spilled fuel is not only a fire hazard, it causes envi-ronmental damage. Wipe up spills immediately.

Fuel can damage paint and plastic. Be carefulnot to spill fuel when filling your fuel tank.Damage caused by spilled fuel is not covered under warranty.

FUEL RECOMMENDATIONS

Use unleaded gasoline with a pump octane ratingof 86 or higher.

These engines are certified to operate on unleadedgasoline. Unleaded gasoline produces fewerengine and spark plug deposits and extendsexhaust system life.

Never use stale or contaminated gasoline or anoil/gasoline mixture. Avoid getting dirt or water inthe fuel tank.

Occasionally you may hear a light ‘‘spark knock’’ or‘‘pinging’’ (metallic rapping noise) while operatingunder heavy loads. This is no cause for concern.

If spark knock or pinging occurs at a steady enginespeed, under normal load, change brands of gaso-line. If spark knock or pinging persists, see anauthorized servicing dealer.

Running the engine with persistent spark knockor pinging can cause engine damage.

Running the engine with persistent spark knockor pinging is considered misuse, and Hypro’sLimited Warranty does not cover parts dam-aged by misuse.

ENGINE OIL LEVEL CHECK

Check the engine oil level with the engine stoppedand in a level position.

1. Remove the filler cap/dipstick and wipe it clean.

2. Insert and remove the dipstick without screwing itinto the filler neck. Check the oil level shown on thedipstick.

3. If the oil level is low, fill to the edge of the oil fillerhole with the recommended oil.

4. Screw in the filler cap/dipstick securely.

Running the engine with a low oil level cancause engine damage.

The Low Oil Sensor (applicable engine types) willautomatically stop the engine before the oil levelfalls below safe limit. However, to avoid the incon-venience of an unexpected shutdown, alwayscheck the engine oil level before startup.

ENGINE OIL CHANGE

Drain the used oil while the engine is warm. Warmoil drains quickly and completely.

1. Place a suitable container below the engine tocatch the used oil, and then remove the fillercap/dipstick and the drain plug.

2. Allow the used oil to drain completely, and thenreinstall the drain plug and tighten it securely.

Please dispose of used motor oil in a manner thatis compatible with the environment. We suggestyou take used oil in a sealed container to your localrecycling center or service station for reclamation.Do not throw it in the trash, pour it on the ground, ordown a drain.

3. With the engine in a level position, fill to the outeredge of the oil filler hole with the recommended oil.

ENGINE OIL CAPACITIES:

Part Number HP Oil Capacity

2541-0043 5.5 0.60L 0.63 Qt

2541-0044

2541-0045 6.5

2541-0046

2541-0047 9 1.1L 1.2 Qt

2541-0048 13

2541-0049

2541-0050

2541-0051

Running the engine with a low oil level can causeengine damage.

The Low Oil Sensor (applicable engine types) willautomatically stop the engine before the oil levelfalls below the safe limit.

Maintenance

12

However, to avoid the inconvenience of an unex-pected shutdown, fill to the upper limit, and checkthe oil level regularly.

4. Screw in the filler cap/dipstick securely.

SERVICING YOUR ENGINEENGINE OIL RECOMMENDATIONS

Oil is a major factor affecting performance andservice life. Use 4-stroke automotive detergent oil.

SAE 10W-30 is recommended for general use.Other viscosities shown in the chart may be usedwhen the average temperature in your area is with-in the recommended range.

The SAE oil viscosity and service classification arein the API label on the oil container. We recom-mend that you use API SERVICE Category SG orSH oil.

AIR FILTER INSPECTION

Remove the air cleaner cover and inspect the filter.Clean or replace dirty filter elements. Alwaysreplace damaged filter elements. If equipped withan oil-bath air cleaner, also check the oil level.

AIR CLEANER SERVICE

A dirty air filter will restrict air flow to the carburetor,reducing engine performance.

If you operate the engine in very dusty areas, cleanthe air filter more often than specified in the MAIN-TENANCE SCHEDULE.

Operating the engine without an air filter, orwith a damaged air filter, will allow dirt to enterthe engine, causing rapid engine wear. Thistype of damage is not covered by Hypro’sLimited Warranty.

Maintenance

13

Dual-Filter Element Types

1. Remove the wing nutfrom the air cleanercover, and remove the aircleaner cover.

2. Remove the wing nutfrom the air filter, andremove the filter.

3. Remove the foam filterfrom the paper filter.

4. Inspect both air filterelements, and replacethem if they are dam-aged. Always replace thepaper air filter element atthe scheduled interval.

5. Clean the air filter elements if they are to bereused.

Paper air filter element: Tap the filter element sev-eral times on a hard surface to remove dirt, or blowcompressed air [not exceeding 30 psi (207 kPa)]through the filter element from the inside. Never tryto brush off dirt; brushing will force dirt into thefibers.

Foam air filter element: Clean in warm, soapywater, rinse, and allow drying thoroughly. Or cleanin nonflammable solvent and allow drying. Dip thefilter element in clean engine oil, and then squeezeout all excess oil. The engine will smoke whenstarted if too much oil is left in the foam.

1. Using a moist rag, wipe dirt from the inside of theair cleaner base and cover. Be careful to preventdirt from entering the air duct that leads to the car-buretor.

2. Place the foam air filter element over the paperelement, and reinstall the assembled air filter. Besure the gasket is in place beneath the air filter.Tighten the air filter wing nut securely.

3. Install the air cleaner cover, and tighten the coverwing nut securely.

Oil-Bath Type

1. Remove the wing nut, and remove the air clean-er cap and cover.

2. Remove the air filter from the cover, wash thecover and filter in warm, soapy water, rinse, andallow drying thoroughly. Or clean in nonflammablesolvent and allow drying.

3. Dip the filter in clean engine oil, and thensqueeze out all excess oil. The engine will smoke iftoo much oil is left in the foam.

4. Empty the used oil from the air cleaner case,wash out any accumulated dirt with nonflammablesolvent, and dry the case.

5. Fill the air cleaner case to the OIL LEVEL markwith the same oil that is recommended for theengine. Oil capacity: 2.0 US oz (60 cm3 )

6. Reassemble the air cleaner, and tighten the wingnut securely.

Maintenance

14

SEDIMENT CUP CLEANING

1. Move the fuel valve to the OFF position, andthen remove the fuel sediment cup and O-ring.

Gasoline is highly flammable and explosive. Youcan be burned or seriously injured when han-dling fuel.

• Keep heat, sparks and flame away.• Handle fuel only outdoors.• Wipe up spills immediately.

2. Wash the sediment cup and O-ring in nonflam-mable solvent, and dry them thoroughly.

3. Place the O-ring in the fuel valve, and install thesediment cup. Tighten the sediment cup securely.

4. Move the fuel valve to the ON position, andcheck for leaks. Replace the O-ring if there is anyleakage.

SPARK PLUG SERVICE

Recommended spark plugs: F7RTC or other equiv-alents.

An incorrect spark plug can cause engine damage.

1. Disconnect the spark plug cap, and remove anydirt from around the spark plug area.

2. Remove the spark plug with a spark plugwrench.

3. Inspect the spark plug. Replace it if the elec-trodes are worn, or if the insulator is cracked orchipped.

4. Measure the spark plug electrode gap with asuitable gauge.

The gap should be 0.028 -0.031 in (0.70 - 0.80mm). Correct the gap, if necessary, by carefullybending the side electrode.

5. By hand, install the spark plug carefully to avoidcross-threading.

6. After the spark plug seats, tighten with a sparkplug wrench to compress the washer.

If reinstalling the used spark plug, tighten 1/8 - 1/4 turn after the spark plug seats.

If installing a new spark plug, tighten 1/2 turn afterthe spark plug seats.

A loose spark plug can overheat and damagethe engine. Over tightening the spark plug candamage the threads in the cylinder head.

7. Attach the spark plug cap.

IDLE SPEED ADJUSTMENT

1. Start the engine outdoors, and allow it to warmup to operating temperature.

2. Move the throttle lever to its slowest position.

3. Turn the throttle stop screw to obtain the stan-dard idle speed.

Standard idle speed: 1,400±150 rpm

Maintenance

15

SPARK ARRESTER SERVICE (optional equipment)

Your engine is not factory-equipped with a sparkarrester. In some areas, it is illegal to operate anengine without a spark arrester. Check local lawsand regulations. A spark arrester is available fromauthorized servicing dealers.

The spark arrester must be serviced every 100hours to keep it functioning as designed.

If the engine has been running, the muffler will bevery hot. Allow the muffler to cool before servicingthe spark arrester.

1 Remove the three 4 mm screws from the exhaustdeflector, and remove the deflector.

2. Remove the four 5 mm screws from the mufflerprotector, and remove the muffler protector.

3. Remove the 4 mm screw from the spark arrester,and remove the spark arrester from the muffler.

4. Use a brush to remove carbon deposits from thespark arrester screen. Be careful to avoid damag-ing the screen.

The spark arrester must be free of breaks andholes. Replace the spark arrester if it is damaged.

5. Install the spark arrester, muffler protector andexhaust deflector in reverse order of disassembly.

Maintenance

16

STORING YOUR ENGINE Storage Preparation

Proper storage preparation is essential for keepingyour engine trouble free and looking good. The fol-lowing steps will help to keep rust and corrosionfrom impairing your engine’s function and appear-ance, and will make the engine easier to start afterstorage.

Cleaning

If the engine has been running, allow it to cool for atleast half an hour before cleaning. Clean all exteriorsurfaces, touch up any damaged paint, and coatother areas that may rust with a light film of oil.

Using a garden hose or pressure washingequipment can force water into the air cleaneror muffler opening. Water in the air cleaner willsoak the air filter, and water that passesthrough the air filter or muffler can enter thecylinder, causing damage.

Water contacting a hot engine can cause dam-age. If the engine has been running, allow it tocool for at least half an hour before washing.

Fuel

Gasoline will oxidize and deteriorate in storage. Oldgasoline will cause hard starting, and it leaves gumdeposits that clog the fuel system. If the gasoline inyour engine deteriorates during storage, you mayneed to have the carburetor and other fuel systemcomponents serviced or replaced.

The length of time that gasoline can be left in yourfuel tank and carburetor without causing functionalproblems will vary with such factors as gasolineblend, your storage temperatures, and whether thefuel tank is partially or completely filled. The air in apartially-filled fuel tank promotes fuel deterioration.Very warm storage temperatures accelerate fueldeterioration. Fuel deterioration problems mayoccur within a few months, or even less if the gaso-line was not fresh when you filled the fuel tank.

Hypro’s Limited Warranty does not cover fuelsystem damage or engine performance prob-lems resulting from neglected storage prepara-tion.

You can extend fuel storage life by adding a fuelstabilizer that is formulated for that purpose, or youcan avoid fuel deterioration problems by drainingthe fuel tank and carburetor.

Adding a Fuel Stabilizer to Extend FuelStorage Life

When adding a fuel stabilizer, fill the fuel tank withfresh gasoline. If only partially filled, air in the tankwill promote fuel deterioration during storage. If youkeep a container of gasoline for refueling, be surethat it contains only fresh gasoline.

1. Add fuel stabilizer following the manufacturer’sinstructions.

2. After adding a fuel stabilizer, run the engine out-doors for 10 minutes to be sure that treated gaso-line has replaced the untreated gasoline in the car-buretor.

3. Stop the engine, and move the fuel valve to theOFF position.

Draining the Fuel Tank and Carburetor

1. Place an approved gasoline container below thecarburetor, and use a funnel to avoid spilling fuel.

2. Remove the carburetor drain bolt and sedimentcup, and then move the fuel valve lever to the ONposition.

3. After all the fuel has drained into the container,reinstall the drain bolt and sediment cup. Tightenthem securely.

Storage/Transportation

17

Storage Precautions

1. Change the engine oil.

2. Remove the spark plugs.

3. Pour a tablespoon (5-10 cc) of clean engine oilinto the cylinder.

4. Pull the starter rope several times to distributethe oil in the cylinder.

5. Reinstall the spark plugs.

6. Pull the starter rope slowly until resistance is felt.This will close the valves so moisture cannot enterthe engine cylinder. Return the starter rope gently.

If your engine will be stored with gasoline in the fueltank and carburetor, it is important to reduce thehazard of gasoline vapor ignition. Select a well-ven-tilated storage area away from any appliance thatoperates with a flame, such as a furnace, waterheater or clothes dryer. Also avoid any area with aspark-producing electric motor, or where powertools are operated.

If possible, avoid storage areas with high humidity,because that promotes rust and corrosion.

Unless all fuel has been drained from the fuel tank,leave the fuel valve lever in the OFF position toreduce the possibility of fuel leakage.

Position the equipment so the engine is level.Tilting can cause fuel or oil leakage.

With the engine and exhaust system cool, cover theengine to keep out dust. A hot engine and exhaustsystem can ignite or melt some materials. Do notuse sheet plastic as a dust cover. A nonporouscover will trap moisture around the engine, promot-ing rust and corrosion.

If equipped with a battery for an electric starter,recharge the battery once a month while the engineis in storage. This will help to extend the service lifeof the battery.

Removal from Storage

Check your engine as described in the sectionCHECK BEFORE OPERATION.

If the fuel was drained during storage preparation,fill the tank with fresh gasoline. If you keep a con-tainer of gasoline for refueling, be sure that it con-tains only fresh gasoline. Gasoline oxidizes anddeteriorates over time, causing hard starting.

If the cylinders were coated with oil during storagepreparation, the engine may smoke briefly at start-up. This is normal.

TRANSPORTING

If the engine has been running, allow it to cool for atleast 15 minutes before loading the engine-pow-ered equipment on the transport vehicle. A hotengine and exhaust system can burn you and canignite some materials.

Keep the engine level when transporting to reducethe possibility of fuel leakage. Move the fuel valvelever to the OFF position.

Storage/Transportation

18

ENGINE WILL NOT START Possible Cause Correction

1. Electric starting: Battery discharged. Recharge battery.check battery.

2. Check control positions. Fuel valve OFF. Move lever to ON.

Choke OPEN. Move lever to CLOSE unless engine is warm.

Engine switch OFF. Turn engine switch to ON.

3. Check fuel. Out of fuel. Refuel.

Bad fuel; engine stored without Drain fuel tank and carburetor. treating or draining gasoline, or Refuel with fresh gasoline.refueled with bad gasoline.

4. Remove and inspect Spark plugs faulty, fouled, or Gap, or replace spark plugs.spark plugs. improperly gapped.

Spark plugs wet with fuel Dry and reinstall spark plugs.(flooded engine). Start engine with throttle lever

in FAST position.

5. Other conditions. Fuel filter clogged, carburetor Replace or repair faultymalfunction, ignition malfunction, components as necessary.valve stuck, etc.

ENGINE LACKS POWER Possible Cause Correction

1. Check air filter. Filter element(s) clogged. Clean or replace filter element(s).

2. Check fuel. Out of fuel. Refuel.

Bad fuel; engine stored without Drain fuel tank and carburetor. treating or draining gasoline, or Refuel with fresh gasoline.refueled with bad gasoline.

3. Other conditions. Fuel filter clogged, carburetor Replace or repair faulty malfunction, ignition malfunction, components as necessary.valve stuck, etc.

Troubleshooting

19

TECHNICAL INFORMATION Serial Number Location

Record the engine serial number in the spacebelow. You will need this serial number when order-ing parts and when making technical or warrantyinquiries.

Engine serial number: ______________________

Battery Connections for Electric Starter

Use a 12-volt battery with an ampere-hour rating ofat least 18 Ah.

Be careful not to connect the battery in reversepolarity, as this will short circuit the battery chargingsystem. Always connect the positive (+) batterycable to the battery terminal before connecting thenegative (-) battery cable, so your tools cannotcause a short circuit if they touch a grounded partwhile tightening the positive (+) battery cable end.

A battery can explode if you do not follow thecorrect procedure, seriously injuring anyonenearby.

Keep all sparks, open flames and smokingmaterials away from the battery.

1. Connect the battery positive (+) cable to thestarter solenoid terminal as shown.

2. Connect the battery negative (-) cable to anengine mounting bolt, frame bolt, or other goodengine ground connection.

3. Connect the battery positive (+) cable to the battery positive (+) terminal.

4. Connect the battery negative (-) cable to the battery negative (-) terminal.

5. Coat the terminals and cable ends with grease.

Remote Control Linkage

The throttle and choke control levers are providedwith holes for optional cable attachment. The fol-lowing illustrations show installation examples for asolid wire cable and for a flexible, braided wirecable. If using a flexible, braided wire cable, add areturn spring as shown.

It is necessary to loosen the throttle lever frictionnut when operating the throttle with a remotely-mounted control.

Models: 2541-0043 thru 2541-0046

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Models: 2541-0047 thru 2541-0051

Carburetor Modification for High AltitudeOperation

At high altitude, the standard carburetor air-fuelmixture will be too rich. Performance will decrease,and fuel consumption will increase. A very rich mix-ture will also foul the spark plug and cause hardstarting. Operation at an altitude that differs fromthat at which this engine was certified, for extendedperiods of time, may increase emissions.

High altitude performance can be improved by spe-cific modifications to the carburetor. If you alwaysoperate your engine at altitudes above 5,000 feet(1,500 meters), have your servicing dealer performthis carburetor modification. This engine, whenoperated at high altitude with the carburetor modifi-cations for high altitude use, will meet each emis-sion standard throughout its useful life.

Even with carburetor modification, engine horse-power will decrease about 3.5% for each 1,000-foot(300-meter) increase in altitude. The effect of alti-tude on horsepower will be greater than this if nocarburetor modification is made.

When the carburetor has been modified for highaltitude operation, the air-fuel mixture will betoo lean for low altitude use. Operation at alti-tudes below 5,000 feet (1,500 meters) with amodified carburetor may cause the engine tooverheat and result in serious engine damage.For use at low altitudes, have your servicingdealer return the carburetor to original factoryspecifications.

Oxygenated Fuels

Some conventional gasolines are being blendedwith alcohol or an ether compound. These gaso-lines are collectively referred to as oxygenatedfuels. To meet clean air standards, some areas useoxygenated fuels to help reduce emissions.

If you use an oxygenated fuel, be sure it is unlead-ed and meets the minimum octane rating require-ment.

Before using an oxygenated fuel, try to confirm thefuel’s contents. Some areas require this informationto be posted on the pump.

The following are the EPA-approved percentages ofoxygenates:

ETHANOL – (ethyl or grain alcohol) 10% by volume. You may use gasoline containing up to10% ethanol by volume.

Gasoline containing ethanol may be marketedunder the name ‘‘Gasohol.’’

MTBE – (methyl tertiary butyl ether) 15% by volume. You may use gasoline containing up to15% MTBE by volume.

METHANOL – (methyl or wood alcohol) 5% byvolume. You may use gasoline containing up to 5%methanol by volume, as long as it also containscosolvents and corrosion inhibitors to protect thefuel system. Gasoline containing more than 5%methanol by volume may cause starting and/or performance problems. It may also damage metal,rubber, and plastic parts of your fuel system.

If you notice any undesirable operating symptoms,try another service station, or switch to anotherbrand of gasoline.

Fuel system damage or performance problemsresulting from the use of an oxygenated fuel con-taining more than the percentages of oxygenatesmentioned above are not covered under warranty.

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EMISSION CONTROL SYSTEMINFORMATION Source of Emissions

The combustion process produces carbon monox-ide, oxides of nitrogen, and hydrocarbons. Controlof hydrocarbons and oxides of nitrogen is veryimportant because, under certain conditions, theyreact to form photochemical smog when subjectedto sunlight. Carbon monoxide does not react in thesame way, but it is toxic.

This utilizes lean carburetor settings and other sys-tems to reduce the emissions of carbon monoxide,oxides of nitrogen and hydrocarbons.

Tampering and Altering

Tampering with or altering the emission control sys-tem may increase emissions beyond the legal limit.Among those acts that constitute tampering are:

• Removal or alteration of any part of the intake,fuel or exhaust systems.

• Altering or defeating the governor linkage orspeed-adjusting mechanism to cause the engine tooperate outside its design parameters.

Problems that may Affect Emissions

If you are aware of any of the following symptoms,have your engine inspected and repaired by yourservicing dealer.

• Hard starting or stalling after starting • Rough idle • Misfiring or backfiring under load• Afterburning (backfiring)• Black exhaust smoke or high fuel consumption

Replacement Parts

The emission control systems on your engine weredesigned, built. We recommend the use of genuineparts whenever you have maintenance done.These original-design replacement parts are manu-factured to the same standards as the originalparts, so you can be confident of their performance.The use of replacement parts that are not of theoriginal design and quality may impair the effective-ness of your emission control system.

A manufacturer of an aftermarket part assumes theresponsibility that the part will not adversely affectemission performance. The manufacturer orrebuilder of the part must certify that use of the partwill not result in a failure of the engine to complywith emission regulations.

Maintenance

Follow the maintenance schedule. Remember thatthis schedule is based on the assumption that yourmachine will be used for its designed purpose.Sustained high-load or high-temperature operation,or use in unusually wet or dusty conditions, willrequire more frequent service.

Engine Tune-up

ITEM SPECIFICATION

Spark plug gap 0.028-0.031 in(0.70-0.80 mm)

Valve clearance IN: 0.15±0.02 mm (cold)EX: 0.20±0.02 mm (cold)

Other specifications No other adjustments needed

CONSUMER INFORMATION

For technical assistance, contact the HyproTechnical/Application Department by phone at 1-800-PowerPro (800-769-3777) or by email attechnical@hypropumps.com.

QUICK REFERENCE INFORMATION

Engine Oil Type SAE 10W-30, API SG or SH, for general use

Capacity 2541-0043 thru 0046 0.6 L (0.63 qt)2541-0047 thru 0051 1.1 L (1.2 qt)

Spark Plug Type LD - F7RTC or NGK – BPR6ES

Gap 0.028 - 0.031 in (0.70 - 0.80 mm)

Carburetor Idle speed 1400±150 rpm

Maintenance Each use Check engine oil. Check air filter.

First 20 hours Change engine oil.

Subsequent Refer to the maintenance schedule.

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Specifications

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Engine Replacement Parts

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Wiring Diagrams

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Wiring Diagrams

Engine Type with Oil Alert and without Electric Starting

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BATTERY

Use a battery rated at 12V, 18Ah or more.

Do not reverse polarity. Serious damage to theengine and/or battery may occur.

A battery can explode if you do not follow thecorrect procedure, seriously injuring anyonenearby. Keep all sparks, open flames and smoking materials away from the battery.

Check the electrolyte level to be sure that it isbetween the marks on the case. If the level is belowthe lower mark, remove the caps and add distilledwater to bring the electrolyte level to the uppermark. The cells should be equally full.

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Notes

Limited Warranty on PowerPro Gasoline Engines

Hypro warrants to the original purchaser of its PowerPro gasoline engine to be free from defects in material and workmanshipunder normal use for the period of one (1) year from the date of purchase. This warranty does not cover freight damage, normalwear and tear, or damage caused by misapplication, lack of routine maintenance, negligence, alterations, or repair that affectsthe performance or reliability of the engine (see limitations and exclusions listed below). The repair or replacement of any part orparts under this Limited Warranty shall not extend the terms of the warranty beyond the original warrantable period.

THIS WARRANTY IS EXCLUSIVE. HYPRO MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED, INCLUDING BUT NOTLIMITED TO ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.

Hypro’s obligation under this warranty is, at Hypro’s option, to either repair or replace free of charge, any part, or parts of theengine upon return of the entire product to the Hypro factory in accordance with the return procedures set forth below. THIS ISTHE EXCLUSIVE REMEDY FOR ANY BREACH OF WARRANTY.

LIMITATIONS AND EXCLUSIONS: This Limited Warranty shall not apply to:1. Bent or broken crankshaft or damage caused by vibration related to a bent or broken crankshaft. Also, damage caused by

loose engine mounting bolts or improper or imbalanced accessories.2. Repairs required because of prolonged storage including damage caused by old or contaminated fuel in the fuel tank, fuel

lines or carburetor, sticky valves or corrosion and rust of engine parts.3. Repair required due to overheating. Common causes of overheating are clogged or damaged flywheel, fan, inlet air passages,

cooling fins or air shrouds.4. Damaged or broken parts caused by low oil levels or dirty or improper grade of motor oil.5. Engine tune-ups and normal maintenance services including, but not limited to, fuel and lubricating oil, valve adjustments and

normal replacement of service items.6. Dirt or grit related wear caused by improper air cleaner maintenance. The damages include but not limited to worn pistons,

piston rings, cylinders, valves, valve guides, carburetors and other internal components.7. Engines that have been serviced or repaired with parts or components not manufactured or approved by Hypro.8. Engines that have been serviced by someone other than Hypro or its dealerships.9. Instances when normal use has worn out the component or a engine without any signs of breakage or defects.

IN NO EVENT SHALL HYPRO BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES OF ANY KIND,WHETHER FOR BREACH OF ANY WARRANTY, FOR NEGLIGENCE, ON THE BASIS OF STRICT LIABILITY, OR OTHERWISE.

Return ProceduresAll engines must be flushed of any flammable liquids before being shipped* to Hypro for service or warrantyconsideration.

For technical or application assistance, call the Hypro Technical/Application number: 1-800-PowerPro (800-769-3777). To obtain service, warranty assistance, or a Return Merchandise Authorization number, call the Hypro Service andWarranty number: 1-800-468-3428; or call the Hypro Service and Warranty FAX: (651) 766-6618.

Be prepared to give Hypro full details of the problem, including the following information: 1. Model number, date and the company from whom you purchased your PowerPro engine.2. Approximate number of hours on the engine.3. In what application the engine is currently being used.4. Maintenance that has been done on the engine prior to failure.

Hypro may request additional information to help determine the cause of failure. Contact the factory to receive a returnmaterial authorization number (RMA) before sending the product. The customer is responsible for all transportationcharges related to warranty work. If found warrantable, returned product(s) will be sent back to the customer at Hypro’sexpense. Non-warrantable items will be evaluated and an estimate of repair will be sent to the customer.Please send products back prepaid to:

HYPROAttention: Service Department375 Fifth Avenue NWNew Brighton, Minnesota 55112

* Carriers, including U.S.P.S., airlines, UPS, ground freight, etc., require specific identification of any hazardous materials being shipped. Failure to do so may result in a substantial fine and/or prison term. Check with your shipping company for specific instructions.

Hypro 2007Printed in USA